I have a 2004 polaris 500 ho. late model (internal locking diff) the problem is when its in 2wd and I accelerate at first the rear wheels spin, then as the motor reaches higher rpm, the awd kicks in, even when the awd switch is off. I have had the front diff apart, oil looks good, measured resistance on the actuator coil in the diff. it is just outside of specs. 25.2 ohms is what i should have but 25.6 is what I have. the armature plate is in good shape, as it is wearing right with no warpage. when the awd switch is on it works correctly, all the time through all the engine rpm range. I have to believe that something is telling the diff the engage even when the switch is off, any ideas? I have worked on quite a few quads and this has me perplexed. I have a factory manual. thanks for your time

 

welcome to the forum. there have ben a few post over the years w/ a simular issue of having enough rpms (like doing donuts) that the front automaticly kicks in the front tires. never really could under stand it. maybe do a search to find more infomation on it.

 

replace the armature plate, they get magnetized , slightly warped ,ect and cause this, while your in ther take a real good look at the cage for cracks

 

Thanks, I am planning on replacing the cage, seals, armature, rollers with john deere parts. The oil in it looked fine, but from what ive read on here (and there are lots of posts) the oil is critical. The whole hilliard thing to me is a different animal. Stendori I have seen your name all over the place regarding the awd.

thanks for your time.

 

I have the same thing going on with my 05 Sportsman 800. I am replacing everything that you had mentioned with John Deere parts as well this saturday. I can't wait to have true 2wd to tear around with.

I'll let you know how it goes however everything that I have read about over the past two weeks indicates this will definately resolve the problem.

 

The plastic roller cage on the on the newer centralized single diff hillary vs the older twin hub hillarys both of which were made of metal.

Bad enough to go from two hillarys to only one but to make the single hillary weaker?

Its enought of a problem that aftermarket metal roller cages are available, not sure why Polaris just does not use a strong cage in the first place like they once did.